Aluminium composite material and forming method

ABSTRACT

The invention relates to a method for forming an aluminium composite material which has a core alloy made from an aluminium alloy of type AA5xxx or AA6xxx and at least one outer aluminium alloy layer provided on one or both sides, wherein the aluminium composite material is formed and the outer aluminium alloy layer provided on one or both sides has a yield strength R p0.2  of 25 MPa to 60 MPa in the soft or solution-annealed state. The method enables the production of large-surface, heavily formed aluminium alloy sheet metal parts, in particular also in outer skin quality.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a continuation of PCT/EP2013/072744, filedOct. 30, 2013, which claims priority to European Application No. 12 190672.1, filed Oct. 30, 2012, the entire teachings and disclosure of whichare incorporated herein by reference thereto.

FIELD OF THE INVENTION

The invention relates to a method for forming a metal sheet made from analuminium composite material which has an aluminium core alloy of typeAA5xxx or AA6xxx and at least one outer aluminium alloy layer providedon one or both sides, wherein the aluminium composite material is formedin a forming tool and the outer aluminium alloy layer provided on one orboth sides has a yield strength R_(p0.2) of 25 MPa to 60 MPa in the softor solution-annealed state. In addition, the invention relates to a useof the aluminium composite material in a corresponding forming method aswell as a formed sheet metal part consisting of this aluminium compositematerial.

BACKGROUND OF THE INVENTION

Sheet metal material made from AA6xxx aluminium alloys are used in carsin the body and for body attachments (doors, tailgates, bonnets, etc.).The alloys which are usually used, such as, for example, AA6016 orAA6014, show both a good formability in the delivered state (T4) and asignificant increase in strength after the paint baking cycle, forexample in the case of a cathodic dip painting. The sheet metal materialis solution annealed in the T4 state. For components in the visibleregion, the so-called outer skin parts, a good surface appearance, i.e.a quality with little or no roping, is a further requirement that thealuminium alloys are used.

For components having high requirements on the formability, aluminiummaterials are available on the market which are optimised with respectto formability and at the same time can be used for outer skin parts.However, even these metal sheets which are optimised with respect toformability cannot solve new requirements on the formability. Presently,due to the weight saving potential of aluminium, aluminium solutions aresought after for outer skin components which could not be producedpreviously from aluminium. For example, large-surface side wall parts ofa motor vehicle are produced as a single-part component from a singlealuminium alloy metal sheet. Such large-surface components could not beproduced previously due to the limited formability of the aluminiummaterial. Due to the lack of aluminium solutions, these large-surfacebody components are either produced from steel or the component isdesigned as a multi-part aluminium component, which leads to anincreased effort in production due to additional joining steps.

The applicant has developed a material which fulfils very highrequirements on the formability and is distinguished by high strainvalues in the T4 state. This aluminium composite material has alreadybeen referred to in international patent application WO 2013/037918 A1.The production method of the material indeed targets a maximumformability of the material, however in practice roping effects werevisible which are caused by production.

SUMMARY OF THE INVENTION

The object of the present invention is to extend the forming limits ofaluminium alloys, in particular to extend the forming limits for theAA6xxx and AA5xxx aluminium alloys which are of interest for motorvehicle construction, and to provide a forming method which enables theproduction of large-surface, heavily formed aluminium alloy sheet metalparts, in particular also in outer skin quality. In addition, a use ofan aluminium composite material is proposed and sheet metal parts whichare produced accordingly are provided.

According to a first teaching of the present invention, the demonstratedobject is solved by a method for forming a metal sheet made from analuminium composite material in that:

k _(f,outside) /k _(f,core)<0 0.5,preferably k _(f,outside) /k_(f,core)<0.4

applies for the ratio of the flow stress of the aluminium alloys of thecore and the at least one outer layer in the soft-annealed orsolution-annealed state, and that the frictional shear stress τ_(R)between the tool and the aluminium composite material in the contactsurface reaches the shear flow stress k_(outside) of the outer aluminiumalloy layer at at least one local position in the forming tool duringthe formation of the aluminium composite material.

According to Coulomb's law of friction:

|τ_(R)|=min(k,μ·|P _(N)|)

applies for the frictional shear stress in the contact surface betweenthe forming tool and the outer aluminium layer of the aluminiumcomposite material, wherein τ_(R) represents the frictional shearstress, μ the coefficient of friction and p_(N) the standard contactpressure or the surface pressure which generates the friction, and k theshear flow stress of the softer outer layer of the aluminium compositematerial.

With the function (1) referred to, two ranges result for the absolutevalue of the frictional shear stress:

τ_(R) =μ·|P _(N)|  1.) and

-   -   where: μ·|P_(N)|≦k

τ_(R) =k  2.)

-   -   where μ·|P_(N)|≧k

In the simplest case, μ remains constant throughout the formation suchthat in the case of increasing surface pressure, the frictional shearstress τ_(R) increases linearly. If, however, τ_(R) reaches the shearflow stress k of the material which is in contact with the forming tool,then the frictional shear stress is limited to the shear flow stress k.

Now according to the theory according to Von Mises:

k=k _(f)/√3,

applies for the shear flow stress k and the flow stress k_(f) of amaterial to be formed, wherein k_(f) corresponds to the yield strengthR_(p0.2) determined in the tensile test at 0.2% plastic strain.

The outer, soft aluminium alloy layer, the flow stress k_(f,outside) ofwhich and thus also the shear flow stress k_(outside) of which isconsiderably lower than that of the aluminium core alloy k_(f,core), isin contact with the forming tool. Thus, at least at one local position:

τ_(R) =k _(outside)

applies for the frictional shear stress in contact between the formingtool and the aluminium composite material during the formation.

From this it is clear that the smaller the value k_(outside) of theshear flow stress, with respect to the flow stress k_(f,outside) of theouter aluminium alloy layer, the smaller the frictional force opposingthe movement direction of the material in the tool. As a result, thesheet metal made from the aluminium composite material can be insertedinto a deep drawing tool more easily in this case. This also applies toaluminium composite materials which are provided with an outer aluminiumalloy layer on one side, provided that the softer, outer aluminium alloylayer is substantially in contact with the forming tool.

It was discovered that the claimed material combination consisting of analuminium alloy of type AA5xxx or AA6xxx for the core alloy and a softaluminium alloy layer provided on one or both sides which has a flowstress ratio with respect to the core alloy of smaller than 0.5,preferably smaller than 0.4, enables the frictional shear stress τ_(R)in the aluminium composite material to reach the shear flow stressk_(outside) of the outer aluminium alloy layer at least one localposition during the formation of the aluminium composite material, andlimits this there. A considerably improved formability of the aluminiumcomposite material is hereby achieved in comparison to a monolithicmetal sheet made from the core alloy.

Differently to in the applicant's own WO 2013/037918 A1, a completelynew path is taken, as the present invention includes the influence ofthe frictional shear stress during formation to achieve the degree offorming in the technical teaching. Contrary to the previous approach,therein the effect is used that the frictional shear stress is limitedby the shear flow stress of the softer, outer aluminium alloy layer.

In forming tests with a cross tool on a laboratory scale, it was shownthat in the case of identical tool geometry and comparable lubricantconditions, the hold-down clamp forces could be increased by at least afactor of 2.6, provided that the ratio referred to above of the flowstress k_(f,outside)/k_(f,core) of the aluminium alloys involved isadhered to. The higher possible hold-down clamp force in the cross tooltests suggest a considerably improved formability of the correspondingaluminium composite materials, in particular in a deep drawing process.As the shear flow stress of the softer outer layer is relatively low incomparison to the shear flow stress of the aluminium core alloy, thefrictional shear stress during formation is significantly reduced, whichenables a greater process window. This opens up the possibility, forexample, to be able to produce a single-part side wall of a motorvehicle from aluminium in outer skin quality with an AA6xxx aluminiumalloy, whereby a great potential for cost saving compared to amulti-part aluminium solution results.

The same also applies for the AlMg aluminium core alloys of type AA5xxxwhich are used substantially for inner parts and structural parts, suchthat even large-surface inner parts and structural parts which require ahigh degree of forming can be produced.

According to a further embodiment of the method, the formation comprisesa deep drawing and/or stretch forming process. In these formationprocesses, the frictional shear stress τ_(R) complicates the relativemovement between the sheet metal material and the forming tool. As hasalready been stated, the limitation of the frictional shear stress τ_(R)to the low values of the shear flow stress k_(outside) of the softer,outer aluminium alloy layer leads to an improved deep drawing or stretchforming performance. Thus, a considerably higher degree of forming canbe achieved, as the material can be drawn with lower forces in theformative forming tool.

If, according to a further embodiment of the method according to theinvention, the at least one outer aluminium alloy layer preferably has5% to 15% of the thickness of the entire aluminium composite material,then the technical effect of the method according to the invention canbe used, without the strength of the aluminium composite material beingreduced too much by the outer layers and the proportion thereof of thetotal thickness of the aluminium composite material.

Preferably, the frictional shear stress τ_(R) is enlarged during theformation by an increase of the surface pressure until this reaches theshear flow stress k_(outside) of the outer aluminium alloy layer atleast one local position in the forming tool. Contrary to the previousforming method in which the surface pressure is typically selected to beso large that no wrinkling occurs in the tool, the surface pressure can,for example, be enlarged in order to achieve the advantageous effect ofthe aluminium composite material with regard to the extension of theforming limits. Furthermore, it is conceivable that composite materialshaving a more cost-efficient surface topography having higher frictionalvalues can nevertheless be formed successfully. A more cost-efficientsurface topography can, for example, be provided by a “mill finish”surface topography of the sheet metal, which saves a work step in theform of an additional rolling step for the application of the specifictopography compared to the topography having lubricant pockets which areusually provided in the case of a large degree of forming.

Particularly good forming results were achieved according to a furtherembodiment of the method in that the aluminium alloy of type AA6xxx inthe solution-annealed state or AA5xxx in the soft state has a uniformstrain A_(g) of at least 20%, preferably at least 22%. Examples of thisare aluminium alloys of type AA6016 in the T4 state or the aluminiumalloy AA5182 in the 0 state.

Furthermore, aluminium alloys of type AA6xxx having an elongation atbreak A_(80mm) of at least 24%, preferably at least 26% transversely tothe rolling direction are eligible as materials for the aluminium corealloys. They are suitable in an embodiment which is free of or low inroping, in particular also for outer skin components of a motor vehiclehaving visibility requirements for the surface appearance.

In addition, AlMg Aluminium core alloys of type AA5xxx having a uniformstrain A_(g) of at least 21%, preferably at least 22%, as well as anelongation at break A_(80mm) of at least 25%, preferably at least 26%transversely to the rolling direction are eligible as structural partswhich do not form visible components of a vehicle, therefore, forexample, frame constructions, interior door parts, twist beam axles,etc.

The aluminium core alloys referred to above combine very high strengthswith an already very good forming capability which can be considerablyincreased even further with the method according to the invention.

If an alloy of type AA6xxx is used as an aluminium alloy and analuminium alloy of type AA8xxx is used as at least one outer aluminiumalloy layer or an alloy of type AA5xx is used as an aluminium core alloyand an aluminium alloy of type AA8xxx, AA1xxx, AA5005, AA5005A is usedas at least one outer aluminium alloy layer, then aluminium compositematerials can be produced with established alloys which have extremelygood forming properties.

In a particularly preferred embodiment, the aluminium core alloy is analloy of type AA6016 and the at least one outer alloy layer is an alloyof type AA8079. This combination allows a hold-down clamp force in thecross tool tests referred to above which exceeds the monolithic AA6016variant by more than a factor of 10. These improved forming propertiesare achieved in the cross tool not only in the case of an increase ofthe hold-down clamp force, but also in the case of an enlarged circularblank diameter.

If an aluminium composite material having an aluminium core alloy oftype AA6xxx is formed according to a further embodiment of the methodwhich has a thickness of 0.5 mm to 2.0 mm, preferably 0.8 mm to 1.5 mm,the strength requirements for outer skin parts which occur in motorvehicle construction can be fulfilled together with the increasedrequirements on the formability.

The same also applies for an aluminium core alloy of type AlMg6 and atleast one outer aluminium alloy layer of type AA1050 or AA5005 orAA5005A. For all alloy combinations referred to, the flow stress ratiois k_(f,outside)/k_(f,core)<0.5.

If an aluminium composite material having a core alloy of type AA5xxx,in particular AlMg6, is formed according to a further embodiment of themethod, which has a thickness of 0.5 mm to 3.5 mm, preferably 1.0 mm to2.5 mm, the strength requirements set for structural components forsimultaneously improved formability can be fulfilled.

Both a roll cladding and a simultaneous casting can be used in theproduction of the aluminium alloy composite material. During the rollcladding, firstly a rolling ingot is cast from the aluminium core alloymaterial and is homogenised. Then the coating(s) with the core alloyis/are composed into a packet and is/are heated to the hot rollingtemperature. Alternatively, the homogenisation can also occur after thepacket construction. Subsequently, the heated packet is rolled hot andthen cold to final thickness.

For the AA6xxx materials, the homogenisation of the rolling ingot occursat a temperature of 500° C. to 600° C., preferably 550° C. to 580° C.,for more than an hour. The hot rolling occurs, differently to in theapplicant's own international patent application WO 2013/037918 A1,without hot strip quenching with winding temperatures from 300° C. to400° C. and a typical thickness of 5 to 10 mm. For outer skin parts, afirst cold rolling to 3 to 4 mm is then implemented with subsequentintermediate annealing, for example in the chamber furnace with a metaltemperature of 370° C. to 450° C. for at least 1 h. Due to finalsolution annealing to final thickness at a typical temperature ofapproximately 500° C. to 570° C. with subsequent quenching and naturalaging approximately at room temperature for at least three days, thestrips can be supplied in the T4 state. Optionally, the strips undergo aheat treatment directly after the quenching in order to accelerate thehardening performance during the cathodic dip painting.

For the AA5xxx-based aluminium composite materials, intermediateannealing temperatures and soft annealing temperatures of 300° C. to500° C. are used. Additionally, AA5xxx materials do not pass through aquenching procedure such that the final soft annealing can occur in thechamber furnace or in the continuous furnace. Alternatively,AA5xxx-based aluminium composite materials can also be used directly asa hot strip.

The aluminium alloys AA5182, AA5019, AlMg6, AA6016, AA6014, AA6022,AA6451, and AA 6111 are eligible as materials, for example for the corealloy layer. Aluminium alloys of type AA1xxx or AA8xxx, for exampleAA1050, AA1100, AA1200, AA8011, AA8014, AA8021 and in particular AA8079are preferred as an outer aluminium alloy layer.

According to second teaching of the present invention, the objectdemonstrated above is solved by the use of an aluminium compositematerial which has a core alloy layer made from an aluminium alloy oftype AA5xxx or AA6xxx and at least one outer aluminium alloy layer whichis provided on one or both sides and which has a yield strength R_(p0.2)of 25 MPa to 60 MPa in the soft or solution-annealed state, having aratio of the flow stresses in the soft or solution-annealed state of

K _(f,outside) /k _(f,core)<0.5, preferably k _(f,outside) /k_(f,core)<0.4,

which is used in a forming method according to the invention. The use ofthe aluminium composite material in such a forming method in particularenables the provision of large-surface, single-part sheet metal partsfor motor vehicle construction, either as an outer skin part having anAA6xxx core alloy or as a non-visible structural part having an AA5xxxcore alloy, which require a particularly high degree of forming.

Finally, the object demonstrated above is solved according to a thirdteaching of the present invention by a sheet metal part which is formed,in particular is deep drawn or stretch formed, using the methodaccording to the invention. As has already been stated, the methodaccording to the invention enables large-surface sheet metal parts madefrom a single aluminium composite material to be provided and furtherwork steps, such as, for example, the joining of smaller componentswhich can be assembled into one unit, to be avoided. Thus, considerablylarger and more complexly formed components can be made available.

According to a further embodiment, the sheet metal part is preferably astructural part or an outer skin part of a motor vehicle. For example,the sheet metal part can be a complex floor pan of a floor assembly or aside door interior part, for example if an aluminium core of type AA5xxxis used. Outer skin parts such as mudguards, bonnets and in particularside walls or frames can be provided with an aluminium compositematerial having an AA6xxx core alloy. All sheet metal parts referred torequire a very high degree of forming which can be achieved with theforming method according to the invention combined with the specifiedaluminium composite materials. The possible applications of aluminiummaterials in the motor vehicle can thus be increased once again, as aforming performance which had previously not been achieved is availablefor these materials.

BRIEF DESCRIPTION OF THE DRAWINGS

Below the invention is explained in more detail by means of exemplaryembodiments in connection with the drawing. In the drawing is shown:

FIG. 1 is a schematic, perspective sectional depiction, the cross toolfor the implementation of the deep drawing test.

FIG. 2 is a simplified exploded depiction, the stamp, hold-down clampand matrix of the cross tool from FIG. 1.

FIG. 3 is a diagram, the stamping force depending on the stampdisplacement of the cross tool from FIG. 1 of a monolithic variant oftype AA6016.

FIG. 4 is the diagram from FIG. 3 for implementation of an exemplaryembodiment of the forming method according to the invention.

FIG. 5 is a diagram, flow stresses k_(f) determined from a tensile test,depending on the strain for the materials AA6016, AA5005, AA6463A,AA8079, AA1050.

FIG. 6 shows the flow stresses of the aluminium materials AA1050,AA8079, AA6463A, AA5005 in relation to the flow stress of the aluminiumalloy AA6016.

FIG. 7 is a diagram, the flow stresses of the material AA8079 dependingon the strain in relation to the flow stress of different possible corealloys of type AA 6xxx.

FIG. 8 is a diagram, flow stresses k_(f) depending on the strain for thematerials AlMg6, AA1050, AA5005.

FIG. 9 is a diagram, the flow stresses of the materials AA1050, AA5005depending on the strain in relation to the flow stress of the aluminiummaterial AlMg6.

FIGS. 10 and 11 are two exemplary embodiments of sheet metal partsaccording to the invention.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1, firstly the configuration of the cross tool is depicted in aperspective sectional view, wherein the cross tool comprises a stamp 1,a hold-down clamp 2 and a matrix 3. The sheet 4, which was cladded onboth sides in the case of a clad variant, had, for example, a thicknessof 1.5 mm. This applied both for the clad and for the unclad variant.The sheet metal provided as a circular blank is deep drawn by thestamping force F_(st), wherein the hold-down clamp 2 and the matrix 3were pressed onto the sheet blank with the force F_(N).

The cross-shaped stamp 1 had a width of 126 mm along each of the axes ofthe cross, whereas the matrix had an opening width of 129.4 mm. Thesheet blank made from the aluminium material had different diameters. Acircular blank diameter of 195 mm was started with.

In FIG. 2, the stamp 1, the hold-down clamp 2 as well as the matrix 3and the sheet 4 is depicted again in an exploded view from below.Stresses of the materials during industrial deep drawing tests can becopied with the cross tool and thus the forming performance of thematerial to be tested can be checked. Therein the stamp 1 was lowered inthe direction of the metal sheet with a speed of 1.5 mm per second andthe metal sheet 4 was deep-drawn according to the shape of the stamp.The stamping force and the stamp displacement until tearing of thesample were measured and recorded.

In FIG. 3, the force displacement diagram of the unclad variant havingan aluminium alloy material of type AA6016 is depicted. It can berecognised that in the case of increase of the hold-down clamp forcesfrom 30 to 300 kN, the stamping force increases to a value of more than120 kN, provided at a 23 mm stamp displacement. The higher the hold-downclamp force, the earlier the stamping force increases. At a 26 mm stampdisplacement and a hold-down clamp force of 300 kN, a tearing of thematerial occurs which limits the forming capability of the uncladvariant. If the hold-down clamp force is reduced, the stamp displacementincreases to approximately 35 mm at 75 kN hold-down clamp force untilthe material tears. No tearing of the material occurs at 30 kN.

The conventional method to adjust the hold-down clamp force and thus thefriction in the deep drawing process can be seen by means of FIG. 3. Theperson skilled in the art will attempt to keep the hold-down clampforces as low as possible such that a tearing of the material does notoccur. On the other hand, the person skilled in the art will endeavourto adjust the hold-down clamp forces such that a wrinkling does notoccur. The forming process is, however, limited by the occurrence oftears with the given hold-down clamp force.

FIG. 4 now shows the force displacement diagram for the stamping forceaccording to one exemplary embodiment of the forming method according tothe invention, wherein the sheet metal material is a variant of typeA2-K1-A2 which is clad on both sides. The composition both of the uncladvariant of type AA6016 depicted in FIG. 3 and the corresponding variantwhich is clad on both sides from the diagram in FIG. 4 are depicted inTable 1.

In FIG. 4 it is recognised that the stamping force F_(st) is limited toa maximum of 100 kN, independently of the respective hold-down clampforce F_(N), which was varied from 300 to 450 kN. No tears were shown inthe case of the forming method according to the invention. The materialcould also be deep drawn without tears at hold-down clamp forces of over300 kN with a stamp displacement of more than 35 mm. This means thatduring the forming, the frictional shear stress of the material whichacts against the stamping force F_(st) is limited and indeed to thevalue of the shear flow stress of the outer aluminium alloy layer. Evenat the maximum stamping force of 450 kN, no tearing of the aluminiumcomposite material of the A2-K1-A2 variant results.

The tested aluminium composite materials were produced as follows:

A rolling ingot consisting of an aluminium alloy of type AA 6016 havingthe composition specified in Table 1 was cast, homogenised at 580° C.for more than 2 h and covered on both sides with a cladding material ofalloys A1 A2, A3, A4 and subsequently roll cladded. Therein, the hotstrip having a thickness of 12 mm and a hot rolling final temperature ofat least 300° C. was produced. Subsequently the hot strip was annealedat a strip temperature of 350° C. for more than 2 h and cold rolled to 4mm. To achieve an outer skin quality, i.e. to avoid the so-calledroping, an intermediate annealing occurred at this thickness, whereinthe strip had a temperature of approximately 350° C. for 2 h.Subsequently, the strip made from aluminium composite material was coldrolled to 1.5 mm final thickness and underwent a solution annealing at500° C. to 570° C. with quenching such that the aluminium alloy stripshaving the core alloy K1 were present in the T4 state for the latertests after natural aging at room temperature for approx. 2 weeks.

The aluminium composite materials based on an AlMg6 aluminium core wereproduced as follows: homogenisation of an ingot made from an AlMg6 alloyat 500° C. to 550° C. for more than 2 h, construction of the claddingrolling ingot by coating of the cladding materials on both sides,subsequent roll cladding to 12 mm thickness, implementation of a hotstrip annealing at 350° C. for more than 2 h, cold rolling to 4 mmthickness, intermediate annealing of the cold strip at 350° C. for morethan 2 h and subsequent cold rolling to 1.5 mm final thickness. Insteadof the solution annealing, a soft annealing is implemented in thechamber furnace at 350° C. for 2 hours at the end of the productionprocess.

TABLE 1 Alloy Designation Si Fe Cu Mn Mg Ti AA 1050 A1 0.046 0.32 0.00340.0057 0.0036 0.0149 AA 8079 A2 0.089 0.86 0.0019 0.021 0.0022 0.0061 AA6463A A3 0.25 0.21 0.0014 0.078 0.34 0.016 AA 5005 A4 0.066 0.19 0.1190.121 0.89 0.0039 AA 6016 K1 1.31 0.18 0.016 0.078 0.32 0.0166 AlMg6 K20.091 0.2 0.142 0.25 6.05 0.022

Table 1 shows the different alloy content of the substantial alloycomponents in percentage by weight. All six alloys have, besidesaluminium and the specified alloy components Si, Fe, Cu, Mn, Mg and Ti,impurities which amount individually to a maximum of 0.05% by weight andin total to a maximum of 0.15% by weight. All information in Table 1 is,of course, understood to likewise be in % by weight.

In Table 2, the measured mechanical characteristic values of the usedalloy types are documented. All information was determined in the softor solution-annealed state according to DIN EN ISO 6892-1:2009.

TABLE 2 A_(g) A_(80mm) R_(P0.2) R_(m) A_(g) (smoothed) A_(80mm) (hand)n_(4-6′) r_(8-12′) Alloy Reference MPa MPa % % % % value value AA A1 2674 27.9 28.7 38.6 39.4 0.270 1.180 1050 AA A2 29 81 31.1 31.4 46.0 46.90.253 0.685 8079 AA A3 37 99 21.3 22.5 27.4 28.3 0.321 0.816 6463A AA A445 113 24.7 24.0 30.2 31.1 0.243 0.941 5005 AA K1 114 219 24 23.8 29.529.8 0.277 0.729 6016 AlMg6 K2 156 308 23 22.2 25.9 26.9 0.301 0.676

In a further test, the maximum hold-down clamp forces for differentalloy combinations were determined with different circular blankdiameters. It was shown that, in particular for the A2-K1-A2 variant,which represents an aluminium alloy of type AA6016 clad on both sideswith an aluminium alloy layer of type AA8079, the circular blankdiameter could be enlarged further and tears only occurred at a circularblank diameter of 205 mm and a maximum hold-down clamp force of morethan 105 kN. At circular blank diameters of 195 mm or 200 mm, no tearscould be generated even at the maximum possible hold-down clamp force of600 kN in the forming test. As the monolithic variant already had tearsat a circular blank diameter of 195 mm and a maximum hold-down clampforce of 50 kN, this proves the excellent formability of the cladvariant in the forming method according to the invention. The results ofthe cross tool test are summarised in Table 3.

R_(p0.2) corresponds to the value of k_(f) at 0.2% plastic strain and ismeasurable in the tensile test. In Table 3, additionally the ratiok_(f,outside)/k_(f,core) is entered for a true strain of approx. 0.025which is gleaned from FIGS. 5 to 9 for the respective materialcombination.

TABLE 3 Max. hold-down clamp force Ratio at circulark_(f,outside)/k_(f,core) blank diameter Ratio (true strain 195 200 205R_(p0.2,outside)/ approx. mm mm mm Variant R_(p0.2,core) 0.025) F(kN)F(kN) F(kN) K1 unclad — — Comparison 50 A1-K1-A1 0.23 0.34 Invention 159A2-K1-A2 0.25 0.38 Invention >600 >600 105.0 A3-K1-A3 0.32 0.46Invention 130 A4-K1-A4 0.39 0.53 Comparison 60 K2 unclad — — Comparison75 A1-K2-A1 0.17 0.27 Invention >600 A4-K2-A4 0.29 0.45 Invention >600

The clad aluminium alloy variants A1-K1-A1 and A3-K1-A3 likewise showeda clear increase with regard to the maximum hold-down clamp force at acircular blank diameter of 195 mm. In comparison to the unclad K1variant, the maximum hold-down clamp force which amounted to 50 kN forthe unclad K1 variant increased by a factor of 2.6 (A3-K1-A3 variant) orby a factor of 3.18 (A3-K1-A3 variant). On the other hand, the A4-K1-A4variant enabled no significant increase of the maximum hold-down clampforce compared to the unclad K1 variant.

The measured values depicted in FIGS. 5 to 9 were determined by tensiletest transversely to the roll direction according to DIN EN ISO6892-1:2009. The flow stress k_(f) is depicted depending on the truestrain, wherein the true strain results as follows:

φ=ln(1+ε)

wherein φ indicates the true strain and E the technical strain.

To explain, FIG. 5 shows stress-strain curves for different materials,wherein the flow stress k_(f) is applied compared to the true stress φ.It can be recognised in FIG. 5 that the core material K1 has aconsiderably higher flow stress than the outer cladding layers A1, A2,A3 and A4.

In FIG. 6, the ratios of the flow stresses of the outer aluminium alloylayers are depicted in relation to the flow stress of the core alloylayer K1. All variants A1, A2 and A3 have a ratio ofk_(f,outside)/k_(f,core) of less than 0.5. Only the variant A4, an outeraluminium alloy layer of type AA5005, has a flow stress ratio to analuminium alloy of type AA6016 which is greater than 0.5.

The measured, maximum holding forces for a circular blank diameter of195 mm show that the softer the outer aluminium alloy layer, the greaterthe maximum hold-down clamp forces for constant circular diameter. Asthe deep draw test is a plastic deformation, the solidification of theouter aluminium alloy layer also plays a role, however.

A distinctive effect with respect to the enlargement of the maximumhold-down clamp force can be observed in the comparison of the A1-K1-A1and the A2-K1-A2 variants. It is known from the aluminium alloy of typeAA8079 that this has a relatively low solidification in the case ofplastic strain. This effect appears to favour the maximum achievableresults in the cross tool tests. The combination of an aluminium alloylayer of type AA6016 with an aluminium alloy AA8079, so the A2-K1-A2variant, showed an enormous increase of the hold-down clamp forces toover 600 kN even in the case of an enlargement of the circular blankdiameter to 200 mm, despite a greater flow stress ratio in comparison tothe A1-K1-A1 variant. At the time, the explanation of this result isseen in that the solidification of the outer aluminium alloy layer oftype AA8079 is lower than that of the core material during the plasticdeformation and that hereby the flow of the material is favoured duringthe forming procedure.

FIG. 7 shows the ratios of the flow stresses k_(f,outside) of an outeraluminium alloy layer of type AA8079 in relation to the flow stresses ofdifferent conceivable core alloys of type AA 6xxx. All variants have aratio of k_(f,outside)/k_(f,core) of less than 0.5. Thus it can beexpected that such combinations of AA 6xxx core alloys established inthe automobile industry having an outer aluminium alloy layer of type AA8079 also have the distinctive improvement of the formability referredto above.

Similar results could also be achieved for another core alloy of typeAlMg6, the stress-strain curves of which are depicted in comparison tothe A3 and A4 variants in FIG. 8 in a diagram. FIG. 9 in turn shows theratio of the flow stresses of the outer aluminium alloy layers A3 and A4in relation to the core aluminium alloy layer of type K2. Both aluminiumcomposite materials showed a maximum hold-down clamp force of more than600 kN at a circular blank diameter of 195 mm, whilst the uncladcomparison material K2 already showed tears at a circular blank diameterof 195 mm and a maximum hold-down clamp force of 75 kN.

From these results it is clear that a considerably increase of theforming performance is enabled by skilful selection of the aluminiumcore alloy and the outer aluminium alloy layer. The enormous increaseswith regard to the forming performance which are accompanied byselection of the aluminium composite materials in connection with theforming method according to the invention enable large sheet metalparts, such as, for example, the side wall part of a motor vehicledepicted in FIG. 10 or also the floor pan of a motor vehicle depicted inFIG. 11 by way of example, to be able to be formed in one piece from ametal sheet consisting of an aluminium composite material formed usingthe method according to the invention.

Preferably, components produced according to the method according to theinvention are, for example, visible outer skin parts of a body of amotor vehicle, in particular side wall parts, exterior door parts andexterior tailgate parts as well as bonnets, etc. of a motor vehiclewhich are produced with an aluminium core alloy of type AA6xxx. Inaddition, preferably all other structural and chassis parts, such asinterior door parts, floor pans, etc., which are not visible andlikewise require a very high degree of forming for an economicproduction, are produced with an aluminium core alloy of type A5xxx, forexample with an AA5182 aluminium core alloy.

1. A Method for forming an aluminium composite material which has a corealloy made from an aluminium alloy of type AA5xxx or AA6xxx and at leastone outer aluminium alloy layer provided on one or both sides, themethod comprising forming the aluminium composite material in a formingtool wherein the outer aluminium alloy layer provided on one or bothsides has a yield strength R_(p0.2) of 25 MPa to 60 MPa in the soft orsolution-annealed state, wherein,k _(f,outside) /k _(f,core)<0.5 applies for the flow stresses of thealuminium alloys of the core and of the at least one outer layer in thesoft or solution-annealed state, the frictional shear stress τ_(R)between the tool and the aluminium composite material in the contactsurface reaches the shear flow stress k_(outside) of the outer aluminiumalloy layer at at least one local position in the forming tool duringthe formation of the aluminium composite material and the formationcomprises a deep drawing and/or stretch forming procedure and wherein analloy of type AA6xxx is used as an aluminium core alloy and an aluminiumalloy of type AA8xxx is used as at least one outer aluminium alloy layeror an alloy of type AlMg6 is used as an aluminium core alloy and analuminium alloy of type AA8079, AA1050, AA5005, AA5005A is used as atleast one outer aluminium alloy layer.
 2. The method according to claim1, wherein at least one outer aluminium alloy layer having a thicknessof 5% to 15% of the total aluminium composite material is formed.
 3. Themethod according to claim 1, wherein the frictional shear stress τ_(R)is enlarged during the formation by an increase of the surface pressurebetween the aluminium composite material and the hold-down clamp.
 4. Themethod according to claim 1, wherein an aluminium core alloy of typeAA6xxx or AlMg6 is formed which has a uniform strain A_(g) of at least20%, preferably at least 22%, in the solution-annealed or soft state. 5.The method according to claim 4, wherein an aluminium core alloy of typeAA6016 and at least one outer aluminium alloy layer of type AA8079 isused.
 6. The method according to claim 1, wherein an aluminium compositematerial having an AA6xxx aluminium core alloy having a thickness of 0.5mm to 2.0 mm, preferably 0.7 mm to 1.8 mm, particularly preferably 0.8mm to 1.5 mm, or an aluminium composite material having an AlMg6aluminium core alloy having a thickness of 0.5 mm to 3.5 mm, preferably1.0 mm to 2.0 mm is formed.
 7. A method of using an aluminium compositematerial which has a core alloy made from an aluminium alloy of typeAlMg6 or AA6xxx and at least one outer aluminium alloy layer provided onone or both sides, the outer aluminium alloy layer on one or both sideshas a yield strength R_(p0.2) of 25 MPa to 60 MPa in the soft orsolution-annealed state andK _(f,outside) /k _(f,core)<0.5 applies for the ratio of the flowstresses of the aluminium alloys of the core and of the at least oneouter layer in the soft or solution-annealed state, in a formingprocess, wherein the frictional shear stress τ_(R) between the tool andthe aluminium composite material in the contact surface reaches theshear flow stress k_(outside) of the outer aluminium alloy layer at atleast one local position in the forming tool during the formation of thealuminium composite material and the formation comprises a deep drawingand/or stretch forming procedure; wherein an alloy of type AA6xxx isused as an aluminium core alloy and an aluminium alloy of type AA8xxx isused as at least one outer aluminium alloy layer or an alloy of typeAlMg6 is used as an aluminium core alloy and an aluminium alloy of typeAA8079, AA1050, AA5005, AA5005A is used as at least one outer aluminiumalloy layer.
 8. A deep drawn or stretch formed structural part or outerskin part of a motor vehicle formed with a method according to claim 1.